Floor Tape Store

Friday, July 19, 2013

Lean Quote: The 3 Goals of Change

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.

"Change has a bad reputation in our society. But it isn’t all bad – not by any means. In fact, change is necessary in life – to keep us moving … to keep us growing … to keep us interested … Imagine life without change. It would be static … boring … dull." — Dr. Dennis O’Grady

Change should not be done for the sake of change -- it's a strategy to accomplish some overall goal.

There are three goals of change:
  1. Change the way people think or act in the organization. All change begins with the individual, at a personal level. Unless the individual is willing to change his or her behavior, no real change is possible. Changing behavior requires a change in thinking.
  2. Change the norms. Norms consist of standards, models, or patterns that guide behavior in a group. All organizations have norms or expectations of their members. Change cannot occur until the organization’s norms change.
  3. Changing the organization’s systems or processes. This is the “meat” of the change. Ultimately, all work is a process, and quality improvement requires change at the process and system level. However, this cannot occur on a sustained basis until individuals change their behavior and organizational norms are changed.
Usually organizational change is provoked by some major outside driving force, e.g., substantial cuts in funding, address major new markets/clients, need for dramatic increases in productivity/services, etc. Typically, organizations must undertake organization-wide change to evolve to a different level in their life cycle, e.g., going from a highly reactive, entrepreneurial organization to more stable and planned development. 

Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Wednesday, July 17, 2013

Talking Lean Episode #2 (7-1-2013)



Welcome to episode 2 of “Talking Lean” with Tim McMahon and Jeff Hajek. We had a lot of fun doing the first one, and this second go around is no different. I always come away from discussions with Jeff reinvigorated about continuous improvement. Hopefully, you end up feeling the same way when listening to us.

In this episode, we have a loose theme about taking care of employees. We didn’t really plan it that way, but both of us have a bias towards making Lean work for frontline teams. Because it shows in our writing so often, it really isn’t that big of a surprise that we can link this episode’s articles together with the message of taking care of employees.

As “Talking Lean” is still a new feature, we would certainly appreciate your comments and feedback. You can either posted at the bottom of this page or email me at TIm@aleajourney.com.

To play the MP3 simply click the link below. If you would rather download it, right-click the link and follow the directions in your browsers pop-up window.

 Enjoy the show.


Links from the Show

Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Tuesday, July 16, 2013

Daily Lean Tips Edition #50

For my Facebook fans you already know about this great feature. But for those of you that are not connected to A Lean Journey on Facebook or Twitter I post daily a feature I call Lean Tips.  It is meant to be advice, things I learned from experience, and some knowledge tidbits about Lean to help you along your journey.  Another great reason to like A Lean Journey on Facebook.


Here is the next addition of tips from the Facebook page:

Lean Tip #736 - Times of Great Difficulty Are Times of Great Opportunity. 
These times may not seem ideal at first, but they usually provide keen insight into ideas of great value.  When you are surrounded by problems, you are simultaneously given an opportunity to provide valuable solutions. When times are good and everything is comfortably in order, it’s easy to become complacent and forget how skillful and resourceful you are capable of being.  Troubled times are necessary evils that push you forward, because they eventually end, and the lessons and strengths you gain from them last a lifetime.

Lean Tip #737 - Involve Employees in Decisions That Affect Their Jobs.
Provide them with opportunities to share what they need in order to be successful at their jobs. Whenever possible, include a representative staff member in major planning projects or initiatives. Encourage employees to share and discuss ideas for improvement.

Lean Tip #738 – Use the Right Tools and Skills for the Job
Regardless of your operation – staff motivation is influenced by the following factors: having the right person in the job who is capable of doing it; equipping them to do the job by giving them the right tools and support and finally setting realistic targets that they believe can be achieved.  This shows the staff that we are responding to the challenges of the marketplace and supporting them in every way we can.

Lean Tip #739 - Training is Always Good, It Keeps People Current and Focused On The Job.
Regular, effective and relevant training is massively important and a great motivator. If you want them to perform properly and consistently then you have to give them the tools to do so. Training is always good, it keeps people up to date and focused on the job at hand, it keeps their skills at the forefront and it will show them that management are obviously concerned with how well they do their job, etc. If they are given good quality training that covers the topics and issues they are faced with then they will respond and to a certain extent motivate themselves to stick with what they learn.

Lean Tip #740 - Provide Challenge and Variety in the Workplace
It is important for employees to be challenged or learning new things in their job.  Too often managers don’t allow their employees to expand beyond their areas of expertise.  Managers are fearful that they will need to expend too much energy on training or reviewing work, that there will be too many mistakes, or that the employees don’t want to have to learn more.  Job sharing, job rotations, special projects, strategic offsites, or even including employees in on key decisions can have a significant and positive impact on long term motivation.

Lean Tip #741 - Change Your Mindset About The Cost of Training.
If you think of training as a business expense, that's what it becomes. However, if you think of training as an investment, that's what it becomes. What would you rather do, pay bills or invest in your team? By thinking of training as an investment, you will also expect a return. This focus guides you in everything from selecting the right training to evaluating its results.

Lean Tip #742 - Engage in Ongoing Employee Skill Development
Managerial training responsibilities extend far beyond simply going over work procedures and sending employees to classes when they need to master a new skill. Effective workforce training is an ongoing process that requires supervisors to engage in ongoing skill development with their employees. Managers must engage in informal training needs assessment on an ongoing basis, paying attention to employees' strengths and weaknesses and identifying gaps that can be overcome through training opportunities.

Lean Tip #743 - Convey "What's in It" for the Trainees
In order for employee training to be successful, trainees must know up front how any educational activity they are asked to participate in is relevant to them. When a training program is announced, be sure to specify what employees are likely to get from participating and reinforce that message with consistency throughout the training. Skilled trainers know that helping employees see "what is in it for them" is essential to success.

Lean Tip #744 – Create a Positive Learning Environment To Encourage Development
Creating a positive learning environment will encourage development and help your employees gain confidence in their new position. Trainers should be relaxed and clearly explain the reasoning behind every new exercise and lesson.
Negativity will only inhibit the learning process, so it's important to be patient, allow for mistakes, and always reward new achievements. This positive feedback will reinforce and affirm the efforts of your new recruits, and encourage them to continue learning.

Lean Tip #745 – It’s Critical to Promote Continuous Learning Throughout Employee’s Career
Proper training should not be reserved for new employees. In order to maintain a staff of trained and well-integrated employees, it's critical to promote continuous learning throughout their careers. There are always new things for employees to learn and the rate of change in the business world demands new skills, fresh perspectives and new ideas. Training should be utilized to ensure that your employees are continually learning and improving.

Lean Tip #746 – Lean Managers Share Their Vision With Employees
Few things cause employees to tune out faster than a management team that keeps the company's future direction to itself. Successful Lean leaders see the larger picture and will share the vision.

Lean Tip #747 – Lean Managers Foster Team-Building
Fostering a connected team is an important practice, but before implementing group events and activities, be sure members of your team won't feel left out. Getting to know your team members is generally an effective way to build collaboration and a sense of joint purpose.

Lean Tip #748 – Lean Managers Provide Training To Their Employees
According to a 2011 report from Accenture, 55% of workers in the U.S. say they are under pressure to develop new skills, but only 21% say their companies have provided training to learn those new skills within the last five years. Training is a lever that changes the rate of improvement you can achieve.

Lean Tip #749 – Lean Managers Follow-Through On Employee Ideas
Most employees like to feel their work has meaning. If they don't get this kind of satisfaction, they lose motivation, according to a number of research studies. One sure way to demean an employee's work is to move them off a project before it's completed. Lean leaders must follow-up on employee ideas.

Lean Tip #750 – Lean Managers Eliminate Fear In The Workplace

Managers who rule through rigid control, negativity, and a climate of anxiety and fear don’t trust that they can get things done any other way. Of course, it backfires in the end because fearful employees won’t bring up new ideas for fear of being attacked and won’t be honest about problems. Moreover, very few great people with options are going to want to work for a fear-based manager.

Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Monday, July 15, 2013

Building Basic Communication Skills


A reader recently asked me how to promote a common skill base for communication in regards to a Daily Lean Tip. Proper communication in the workplace is essential so I thought I would share my thoughts here with everyone.

In today's team-oriented workplace, the development of good interpersonal communication skills is an important key to success. With a bit of practice and some instruction, you can be on your way to building positive communication skills to use in your workplace and beyond.

The process of communication involves establishing a link with another person either directly (verbal or non-verbal) or indirectly.

Basic Communication Principles include:
  • Communication is an exchange of information
  • Communication is always and only one to one
  • There are two processes when communicating – sending and receiving
  • As a sender, we can use tools and skills to LINK with another person
  • As a receiver, we can use tools and skills to understand what is being conveyed
  • Information can be exchanged directly through words (verbal) or emotions (non-verbal)
  • Information can be exchanged indirectly through posters, signs, videos, e-mail or voice mail

The attitudes you bring to communication will have a huge impact on the way you compose yourself and interact with others. Choose to be honest, patient, optimistic, sincere, respectful, and accepting of others. Be sensitive to other people's feelings, and believe in others' competence. Good communication must be H.O.T.

H.O.T. stands for honest, open, and two-way.

Communication is a key ingredient for empowerment. Give every employee equal and direct access to information. Many companies have developed a trickle-down style of communication that alienates those employees who may not be "in the loop." The more informed employees are and the more communication is open, honest, direct and complete, the more likely employees are to feel empowered and connected to the daily operations and overall goals of their company.

Open communication is at the center of Lean and Respect for People. Employees need to know what is expected of them and how they’re performing. Visual displays such as scoreboards, scheduling charts, team communication boards, and recognition displays all help to keep information flowing between employees, departments and upper management.

Communication is the glue that binds an organization together but do not assume that several announcements and a note on the notice board is sufficient to get the story out. Some say to communicate seven times and seven ways but that does not mean seven months apart. Develop and implement a robust communication plan and check to see if the total target audience has received the unfiltered message. If you want to know if your message is getting out clearly why not ask the most obscure person on the night shift if he or she heard the message? The day shift is easy but how about the rest of the folks?

To be an effective communicator remember The “Be List”.
  • Be A Teacher
  • Be Enthusiastic
  • Be Positive
  • Be Consistent
  • Be Demanding but Considerate
  • Be Courteous

Not only should one be able to speak effectively, one must listen to the other person's words and engage in communication on what the other person is speaking about. Avoid the impulse to listen only for the end of their sentence so that you can blurt out the ideas or memories your mind while the other person is speaking.

Effective communication is all about conveying your messages to other people clearly and unambiguously. It's also about receiving information that others are sending to you, with as little distortion as possible. Doing this involves effort from both the sender of the message and the receiver.

Developing advanced communication skills begins with simple interactions. Communication skills can be practiced every day in settings that range from the social to the professional. New skills take time to refine, but each time you use your communication skills, you open yourself to opportunities and future partnerships.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Friday, July 12, 2013

Lean Quote: A Strategic Plan Comes To Life Through Discussion and Negotation

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.

"A strategic plan is nothing but a dead letter. It comes to life only through discussion and negotiation." — President Dwight D. Eisenhower

To reduce ambiguity and misinterpretation during the planning phase of Hoshin Kanri management uses a fact-based inter-level negotiation process known as “Catchball”. The word “catchball” denotes a simple social game in Japan in which a circle of young children throw a baseball back and forth. It metaphorically describes a participative process that uses iterative planning sessions to field questions, clarify priorities, build consensus, and ensure that strategies, objectives, and measures are well understood, realistic and sufficient to achieve the objectives.

Hoshin planning begins with the senior management identifying the strategic outcomes/goals to be achieved, complete with deadlines. Once determined, the ‘challenges’ are sent to the operational units who break them down and determine what each unit and person has to do to be able to achieve the management objective. They then bounce the ‘ball’ back to senior management who catches it and determines if the execution committed to will be satisfactory or not. If it is not, the ‘ball’ is bounced back to the operations folks again who catch it and respond accordingly.

The conversation about strategic objectives and means widens as top management deploys its strategy to middle management because managers throw ideas back and forth from one level of the organization to another. There are three major benefits to catchball. First, it opens up new channels of communication between company leaders and process owners, which greatly improves the quality of the organization’s shared knowledge about its processes, people and relationships. Second, it forges new relationships necessary to execute the strategy. Third, by engaging middle and even front line managers in genuine give-and-take negotiations—that is, by getting their buy-in—Hoshin dramatically reduces the cost of getting people to do what they’ve agreed to do.

In short, catchball is a disciplined multi-level planning methodology for “tossing an idea around.” It takes strategic issues to the grassroots level, asking employees at each level of management to “value add” to the plan based on data analysis and experience of their functional areas.

Catchball requires that the people who deploy downward engage in some kind of data-based conversation with the people who design the plans. There must be sufficient coupling and discussion during the planning process to ensure the strategic plan is clear and realistic otherwise it will be nothing but a dead letter.

Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Wednesday, July 10, 2013

5 Ways to Make Your Employees Happy At Work


No matter what type of business you run, you’re going to need your employees to perform well in order to be successful. If you get the most out of your employees, there is no limit on how far you could go. In order to get the most out of your employees, making them happy should be a priority. Here are five ways that you can help your employees be happy about work.

  1. A sense of meaning: Whether on the widget-line or in the executive suite, every employee feels happier knowing that their hard work benefits not just the business but the larger world.
  2. Opportunities for growth: People are happier when they are learning, and they are happier doing their jobs when they feel that they are enjoying continuous opportunities to grow.  A lot of those people are even happier when they know that growth is helping them get to the next rung on their desired career ladder… or lattice.
  3. Offer autonomy to workers: Allowing workers to perform tasks related to their jobs in their own way will not only make workers happier. It will also make them more productive since they will not have to waste time waiting for approval from superiors.
  4. Offer a good training program: Employers shouldn't underestimate the impact training has on employees and their future happiness. A company-sponsored mentorship or structured training sessions are likely to lead to engagement among employees.
  5. Create a favorable office environment: Employees are happier if they like where they work. Simple things such as reducing the length of meetings, providing food to employees in the office, and recognizing employees after a job well done make employees happier. Communication with employees also helps to alleviate many concerns they may have about their job since it helps workers feel happier and more secure at work. Communication either in person, in an email or with a handwritten note all helped to make workers feel better at work.
In general, workplaces that make us feel included, valued, cared for, and competent bring out our best efforts. And while happiness alone may not cause productivity, it’s a pretty solid start. Happier workers stick around longer, bring more energy and enthusiasm to their tasks, and help maintain organizational morale.

Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Tuesday, July 9, 2013

No Time for Improvement Means No Improvement


Whether a company has just switched to Lean production or is still using a traditional manufacturing approach, if it does not establish an official improvement time policy, very little improvement will ever happen there.

We have seen this everywhere, even in companies which loudly proclaim their commitment to continuous improvement. Little or no actual time is set aside to do the very improvement the company says it wants.

It is an age-old battle — production time versus improvement time. Two worthy rivals attempting to occupy the same narrow 24-hour space. The issue is not which is more important. Production is! This is as it should be: a company is in business to sell its products and services. It must first make them. And that takes time. Production time always comes first.

Without an improvement time policy, however, the danger is that needed improvements will never happen.

Too often improvement is left to chance and the ingenuity of the willing to eke out small pockets of time — and make magic happen. We all know these people. They see the vision burning brightly before them and are determined to make it happen. Time and again, these people prove — with their own mental, emotional, and physical health — the familiar adage: Where there’s a will, there’s a way.

In a sad and important way, these quiet heroes do their companies and the rest of us some bit of harm. When they make magic happen, in the absence of a clearly defined, improvement time policy, they unintentionally send the message that separate time is not needed. Wise, indeed, is the company that sees through this double-think and takes steps to establish the policy nevertheless.

Improvement doesn’t just happen.  It takes time, and in the pressure pot of our day to day activities, there is never enough time to improve our situation. The structure of Lean permits and requires time be set aside for improvement. If managers do not definitively provide time for the task of improvement, then people will know that they are not serious about making improvement a formal part of the work.

Most of us don't set aside time in the day, much less the week, just to improve. It doesn't take much time or skill, mainly just will. We need to be encouraged and reminded that it only takes a few minutes to do kaizen. Without assistance from management, people have no good way to make time for improvement within the workday.


There can be no improvement without the time and resource commitment from management to solve problems.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare